Tuesday, December 23, 2008

I buy my zinc for casting at Rotometals.
If anyone knows where to get scrap zinc that would be great to hear from you. Please post a comment.

2" and 1.5" round drill bits make the rings from insulation foam.
The letters are added with a thin cut of the same foam and the the entire model was coated with tape.
A spout is added and also taped around.
The model is buried in play sand and the sand is shaken to get a tight fit around the foam and tape.

Molten zinc is poured on to the foam.

A jig saw is used to cut off the pour spout and the edges are cleaned up with an angle grinder and the residue of the tape is cleaned off with a wire brush.
the full set

Sunday, December 7, 2008

I just cut a shape out of pink insulation foam covered all but the one side of it in masking tape and buried it in play sand.The results were fairly crude but so was my starting form.Definitely something I am going to keep working on.The zinc was melted in a can in a charcoal fire. and poured onto the insulation.The final cast is painted with Testors enamel.